The company’s portfolio includes EMC filters, power magnetic components, power quality filters and the related services. For the automotive industry, Schaffner develops and manufactures antennas used in keyless entry systems for vehicles, and filters for the drive systems of hybrid and electric vehicles and their charging infrastructure. Schaffner components are deployed in electronic motor controls, in wind power and photovoltaic systems, rail technology applications, machine tools and robots, electrical infrastructure, and in power supplies for electronic devices.
Markets That We Serve
Building Technology
Factory Automation
Infrastructure
Machinery
Mobility
Motor Drives
Power Supply
Renewables
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Schaffner offers the world’s broadest selection of EMC/EMI filters and chokes. Standardized and customer-specific solutions – with full engineering support – help to meet international compliance standards and improve the immunity and safety of electrical and electronic equipment.
Electricity supply represents one of the most essential basic services for the support of an industrial society. Power generation, transmission, distribution, and usage are undergoing significant changes due to heavy demand on energy. That will affect the electrical quality and performance needs of all connected energy users.
One major aspect of electrical power is its quality and stability – or so-called power quality. A high level of power quality is needed to enable the reliable function of equipment and systems and can only be guaranteed with reliable partners such as the Schaffner Group. This is true for harmonic distortions which are created by non-linear loads which account for the biggest group of loads in our today’s modern society.
The Schaffner Group offers a unique mixture of knowledge and solutions to help rebuilding and maintaining a quality of the power that is appropriate in terms of local or international standards as well as customer requirements.
Magnetic components are an important element of power electronics engineering. Inductors and transformers are often key for optimizing a system for highest energy yield (e.g. in photovoltaic inverters) or low energy consumption (e.g. for plant-wide optimization).
A line reactor is an inductor which is wired in series between a power source and a load. Line reactors, also called input AC reactors, are generally used in motor drive applications.
The main function of this Schaffner component lies into its current limiting characteristics. Line reactors also reduce the main harmonics, limit the inrush currents, and protect variable frequency drives (VFD) and motors. An overall improvement of the true power factor and the quality of the input current waveform can be achieved. Besides many other high demanding functions, Schaffner custom-made line reactors are used as second harmonic filters in traction rolling stock applications.
Features:
Phases: 1 and 3
Current range: up to 5 kA
Short circuit current withstand: up to 50 kA
Voltage range: up to 36 kV
Fundamental frequency: up to 1 kHz
Switching frequency: up to 20 kHz
Insulation classes: 180/200/220
Protection class: up to IP 67 and NEMA 6/6P
Cooling methods: AN, AF, WD
DC Reactors
The primary purpose of a DC reactor is to smooth the current pulses in DC circuits and to reduce the damaging harmonics on the power line.
Schaffner DC reactors, also called DC link reactors or DC chokes, are typically connected to the semiconductors on the DC bus of converters, inverters and variable frequency drives (VFD).
Features:
Phase: single
Current range: up to 5 kA
Short circuit current withstand: up to 50 kA
Voltage range: up to 36 kV
Ripple frequency: up to 30 kHz
Insulation classes: 180/200/220
Protection class: up to IP 67 and NEMA 6/6P
Cooling methods: AN, AF, WD
Load Reactors
Schaffner load reactors work on the AC output side of frequency converters or other sensitive equipment in series to the electrical consumer.
Load reactors, also known as output reactors or dv/dt reactors, essentially protect the load, normally an electrical motor. It is an efficient way to reduce the high voltage dv/dt caused by the power switching semiconductors within the drive converter. The protection of motor insulation from premature aging and destruction results in a significantly increased lifetime of all motor drive systems.
Features:
Phases: 1 and 3
Current range: up to 5 kA
Short circuit current withstand: up to 50 kA
Voltage range: up to 36 kV
Fundamental frequency: up to 1 kHz
Switching frequency: up to 20 kHz
Insulation classes: 180/200/220
Protection class: up to IP 67 and NEMA 6/6P
Cooling methods: AN, AF, WD
Special Reactors
Advanced reactors
Air core reactors
Common mode (CM) reactors
di/dt reactors
Harmonic compensated reactors
High reactance reactors
Saturable reactors
Swinging reactors
Switching frequency (SF) reactors
Trap reactors
Filters
Sine Wave Filters
Sine wave filters are low pass frequency filters, which convert the rectangular PWM output signal of motor drives into a smooth sine wave voltage with low residual ripple.
Sine wave filters, alternatively called output filters or sinusoidal filters, are mainly used in combination with variable speed drives (VSD) to protect the motor against excessive voltage spikes and overheating. These filters also decrease acoustic switching noise levels and enable longer cable layouts. As a consequence, insulation stress and losses in AC motors are reduced, and therefore prolonging the motor life time.
Features:
Phases: 1 and 3
Current range: up to 5 kA
Short circuit current withstand: up to 50 kA
Voltage range: up to 36 kV
Fundamental frequency: up to 1 kHz
Switching frequency: up to 20 kHz
Insulation classes: 180 / 200 / 220
Protection class: up to IP67 and NEMA 6/6P
Cooling methods: AN, AF, WD
LC – LCL Filters
Schaffner LC- and LCL-filters are harmonic filters usually used on the grid side of renewable energy sources, like wind energy and photovoltaic (PV) plants. These devices improve and ensure the overall power quality of the produced energy.
The filtering of the inverters’ switching frequency is crucial for an optimized system configuration and the fulfilment of national grid standards. We design and produce custom-made LC – LCL filters, compatible with your transformers and other power magnetic components.
Features:
Phases: 1 and 3
Current range: up to 5 kA
Short circuit current withstand: up to 50 kA
Voltage range: up to 36 kV
Fundamental frequency: up to 1 kHz
Switching frequency: up to 20 kHz
Insulation classes: 180 / 200 / 220
Protection class: up to IP67 and NEMA 6/6P
Cooling methods: AN, AF, WD
Dv/Dt Filters
Our dv/dt filters protect motors against high voltage increases and voltage peaks at motor terminals.
Since modern motor solutions consist of variable speed drives (VSD), dv/dt filters are a vital system component. Dv/dt filters allow longer motor cables and are a central element for retrofitting actions. With dv/dt filters, the voltage has still a pulse shaped wave form, though the current is sinusoidal. Due to their lower reactor and capacitor values, generally dv/dt output filters are smaller and lighter in weight than sine wave filters.
Features:
Phases: 1 and 3
Current range: up to 5 kA
Short circuit current withstand: up to 50 kA
Voltage range: up to 36 kV
Fundamental frequency: up to 1 kHz
Switching frequency: up to 20 kHz
Insulation classes: 180 / 200 / 220
Protection class: up to IP67 and NEMA 6/6P
Cooling methods: AN, AF, WD
Transformers
Multi-Pulse Drive Transformers
Schaffner provides isolation multi-pulse drive transformers for variable speed and variable frequency drive applications.
These units, also named rectifier transformers, are not just oversized standard units, but are designed specifically for inherent harmonics, minimal space requirements, and other unique characteristics of drive systems. Schaffner has a long history with major drive manufacturers in several markets. Our experience includes step-up transformers and winding configurations for multi-pulse transformers like 18-, 24- and 36- pulse designs.
Features:
Phases: 1 and 3
Power range: up to 10 MVA
Voltage range: up to 36 kV
Lightning impulse: up to 300 kV
Fundamental frequency: 16 Hz up to 30 kHz
Coil technology: VPI, Magne-seal
Insulation classes: 180 / 200 / 220
Protection class: up to IP67 and NEMA 6/6P
Cooling methods: AN, AF, WD
High Efficiency Transformers
Schaffner high efficiency transformers offer the best ratio between initial cost and operating cost for sensitive applications.
We are experienced in designing the ideal construction and finding the optimum material mix for lower transformer losses. Lowering the energy consumption would result in reduced operating costs and less harmful emissions for your operation.
Features:
Phases: 1 and 3
Power range: up to 10 MVA
Voltage range: up to 36 kV
Lightning impulse: up to 300 kV
Fundamental frequency: 16 Hz up to 30 kHz
Efficiency: up to 99.9 %
Coil technology: VPI, Magne-seal
Insulation classes: 180 / 200 / 220
Protection class: up to IP67 and NEMA 6/6P
Cooling methods: AN, AF, WD
Distribution Transformers
Schaffner is the leading supplier of dry-type transformer products for distribution and trackside power applications. Strong technical expertise and vast application experience allow us to design the best solutions for these demanding applications.
Our products are installed in traction power substations in over 50 cities worldwide and include traction power transformers (TPT), interphase transformers (IPT), auxiliary power transformers (APT), and DC negative return reactors. In addition to that, Schaffner medium voltage (MV) grid step-up transformers support photovoltaic (PV), wind energy, hydro, bio-fuel and energy storage applications worldwide.
Features:
Phases: 1 and 3
Power range: up to 10 MVA
Voltage range: up to 36 kV
Lightning impulse: up to 300 kV
Fundamental frequency: 16 Hz up to 30 kHz
Coil technology: VPI, Magne-seal
Insulation classes: 180 / 200 / 220
Protection class: up to IP67 and NEMA 6/6P
Cooling methods: AN, AF, WD
Middle Frequency Transformers
Schaffner middle frequency (MF) transformers take your high-demand and advanced applications to the next level.
Since the beginning of the MF transformers development, we have been at the cutting edge of this technology. Combining our innovative winding design with carefully selected premium core materials and have achieved maximal values of power density per weight (kW/kg). By applying our customized cooling methods, Schaffner MF transformers prove exceptional reliability in many applications.
Features:
Phases: 1 and 3
Power range: up to 5 MVA
Voltage range: up to 10 kV
Fundamental frequency: 1 kHz up to 30 kHz
Coil technology: VPI, Magne-seal
Insulation classes: 180 / 200 / 220
Protection class: up to IP67 and NEMA 6/6P
Cooling methods: AN, AF, WD
Traction Rolling Stock Transformers
Schaffner brings a wide experience in the traction rolling stock transformer business. Since decades, we design and produce successfully high quality devices and solutions for the railway market.
Our traction rolling stock transfomers stand for exceptional reliability and superior product attributes. Shock and vibration resistance, fire and smoke proof, low weight and a very compact custom design are just a few of our quality characteristics. In traction rolling stock applications the lightning, heating and safety systems of locomotives and railway carriages are typically supplied by a Schaffner auxiliary transformer or a head end power (HEP) transformer.
Features:
Phases: 1 and 3
Power range: up to 2 MVA
Voltage range: up to 5 kV
Fundamental frequency: 50 Hz / 60 Hz
Switching frequency: 600 Hz up to 34 kHz
Coil technology: VPI, Magne-seal
Insulation classes: 180 / 200 / 220
Protection class: up to IP67 and NEMA 6/6P
Cooling methods: AN, AF, ON/OF
Technologies
Magne-seal
Schaffner’s exclusive Magne-Seal design provides the solution for premium-duty sealed transformer needs in heavy commercial and industrial applications. It combines the environmentally friendly, cost-effective, flexible design benefits of dry-type transformers and the protection capabilities of cast coil and liquid-filled transformers.
The Product:
Magne-Seal begins in the coil winding process using special techniques to install materials that create a seal at the bottom of each winding layer. Coils are then pre-baked to thoroughly dry them for varnish processing. During a two-step vacuum pressure impregnation (VPI) process, every layer of conductor and insulation material is filled with varnish like a column. After baking the coils to cure the VPI process, a final high-build polyester varnish finish is applied.
The finished Magne-Seal product provides coils that are completely sealed against the environment. All Magne-Seal materials – Nomex insulation, polyester varnish, sealing materials – are fully rated for a 220º C insulation system.
Environmental Advantages:
1. No Fluid Containment Required – Magne-Seal is a dry transformer and contains no fluids. It doesn’t require expensive basins to contain potential spills and eliminates the concern of transformer fluids escaping containment barriers.
2. Fire Resistant – MagneSeal has successfully passed fire testing that verifies the materials used to construct it do not support combustion.
No explosion barriers or blast containment are required.
Design Advantages:
1. Higher Overload Capability – All the materials used in the Magne-Seal insulation system are fully rated for 220º C. Epoxy materials used in cast coil and other designs are rated for much lower temperatures. Magne-Seal is able to deliver 15-30% more overload capacity than designs that use epoxy materials.
2. Smaller Footprint – The Magne-Seal processing system doesn’t restrict the use of coil cooling ducts. This allows MTC designers to provide an efficient convection cooling system that requires less floor space. Magne-Seal footprints are typically 10-20% smaller than cast coil footprints.
3. Flexibility – Since Magne-Seal isn’t cast in a mold, designs aren’t restricted by mold sizes. Schaffner designers have available a full range of coil geometries and winding configurations to provide electrical parameters and physical dimensions exactly as specified.
4. Cost Effective – No molds, expensive casting equipment, or epoxy insulation are required. Magne-Seal provides a sealed coil transformer efficiently and effectively.
AUTOMOTIVE
Schaffner solutions for use in e-mobility can be found in automotive power electronics (EMI filters, magnetic components), keyless locking systems (passive entry/passive go), electronic immobilizers and tire pressure monitoring systems (TPMS).
HV DC filter is wired between DC bus of power electronic and high voltage battery. The main function of this Schaffner filter is to reduce EMI noise and meet the stringent automotive standards.
Power electronics converters and HV battery are the key components for e-mobility development. Highly integrated power electronics converters generate EMI noise while HV batteries are very susceptible to it.
Schaffner HV DC filter is a compact and cost effective solution to reduce EMI noise and protect the HV battery.
Features:
Maximum operation voltage: 600 VDC
Rated current: 150 A, 250 A, 500 A
High attenuation for common and differential mode between 10 kHz up to 300 MHz
Temperature range: -40°C to +110°C
Dimension: 120x95x56 mm (150 A, 250 A), 146x90x60 mm (500 A)
Weight: 750 g (150 A, 250 A), 1140 g (500 A)
Customization is available upon request
Common Mode Choke
Schaffner provides horizontal and vertical common mode chokes for automotive application with rated current from 16 A to 50 A.
Schaffner common chokes are attenuating common and differential mode EMI noise, by being connected to AC-AC or DC-DC automotive power electronics. The benefits of chokes are high attenuation, good temperature behavior, compact design, multiple PCB-mounting options.
Features:
Inductance range: 0.33 mH-1mH*
Maximum operation voltage: 600 VAC/1000 VDC
Current range: 16 A-50 A
Temperature operation: -40°C to +125°C
Multiple PCB mounting options
Compact design
Customization in accordance with customer’s design is available upon request
Magnetic Component
Inductors
Schaffner provides inductors for automotive DC-DC converters for various range of power.
Schaffner inductors are combining innovative winding design with carefully selected core materials to achieve optimized construction with maximal power density, low losses and robust mechanical design. Schaffner also provides inductors integrated together with the EMI filter.
Features:
Inductance range: 10 uH-1.5 mH
Current range: 5 A-300 A
Switching frequency: 5 kHz- 200 kHz
Temperature operation: -40°C to +180°C
Low power losses
High temperature stability
Low level of audible noise
Mechanical robustness
Customization to customer’s design is available upon request
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